Extension Housing Gasket - Four Wheel Drive (4WD): Installation

WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Lightly lubricate the gasket with petroleum jelly to hold it in place during assembly.

Install the new extension housing gasket.

Fig 1: Locating Extension Housing Gasket

Courtesy of FORD MOTOR CO.

Install the extension housing bolts.
- Tighten to 47 Nm (35 lb-ft).

Fig 2: Locating Transmission Extension Housing Bolts

Courtesy of FORD MOTOR CO.

Connect the OSS sensor.

Fig 3: Identifying Output Shaft Speed (OSS) Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Using the special tool, install a new output shaft retaining nut.
- Tighten to 200 Nm (148 lb-ft).

Fig 4: Identifying Output Shaft With Special Tool

Courtesy of FORD MOTOR CO.

Install the transfer case. For additional information, refer to TRANSFER CASE article.
Start the engine. Move the transmission range selector lever through all the gear ranges, checking for engagements.
With the vehicle in NEUTRAL, engine running and the transmission at normal operating temperature 66-77°C (150-170°F), check and adjust the transmission fluid level, and check for any leaks. If fluid is needed, add fluid in increments of 0.24L (0.5 pt) until the correct level is achieved (fluid should be in the hot range cross-hatched area of the fluid level indicator).